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BEE: Best Practices in Energy
Efficiency in Cement Sector
Ambuja Cements Ltd. (MCW)
1 2015
Presented by: Mr. Vijay Agrawal, GM (Production) [email protected]
Mr. Sheshmani Shukla, Sr. Manager [email protected]
2015 2
1. Electrical energy reduction in Cement mills by Grinding media optimization 2. Improving Clinker quality & increasing fly ash absorption 3. Installation of Efficient Turbo Blowers 4. Optimization of compressors 5. Cooler fans’ Inlet modification 6. Best practices of maintenance
Cement Plant:
Power Plant: 1. Retrofitting of MP turbine to HP turbine
2. Reduction of Aux. power consumption by various measures.
3
40.10 39.56 39.83 38.86 40.86 42.67 44.4846.79
57.2947.55 43.72 40.16 39.79 41.65 39.52 37.69 36.67
126 125 125
128
122120
118
121124 124
132 131 131
124
129
138140
6.05 6.07 6.04 6.12 5.22 4.62 4.77 5.01 5.07 4.98 5.2 4.9 5.18 4.93 5.34 5.12 5.55
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
105
110
115
120
125
130
135
140
145
Total Sp. Power (Kw/T cem) Production rate (T/H) Residue %
Before After
Reduction in specific electrical energy consumption in Cement Mill No. 3 by
4 kWh/t cement
4
Sr No. Actions taken
1 Media pattern change, increased finer ball charge in 2nd chamber
2 Replacement of Worn out intermediate diaphragm plates, Separator static & rotor vanes
3 Sepol inlet duct air guide vanes adjusted.
4 Sepol bag filter exit & Fresh air blancing done to get max. separation efficiency.
5 Regular Inspection of Separator fan & cleaning of inlet box.
6 Regular Inspection of BE lip plate for any recirculation.
7 Mill discharge hood modification to increased fineness of bag filter product .
8 Hood arrangement for all aux. equipment venting
5
Change of the raw mix design :
Silica Ratio increased from 2.38 to 2.48
Liquid content reduced from 26.81 to 26.53
High purity corrective material used to maintain raw mix composition
without increasing limestone pile LS target.
The raw mix control QCX-online done on moduli value.
Limestone Saturation factor reduced from 115.1 to 112.7.
Change in Clinker Quality Clinker LSF maintained at same level of 92%.
Clinker SR increased from 2.38 to 2.45.
Clinker AR increased from 1.46 to 1.52.
Improvement in clinker strength.
Year LSF
2013 115.1
2014 113.8
2015 112.7
6
Increase in Fly ash Absoprtion
% Fly ash
year 2013 27.70
year 2014 30.00
year 2015 (Updated) 31.60
30
35
40
2013 2014 2015 MayYTD
37.40 36.20
35.59
Up
to C
inke
riza
tio
n
K
wh
/t c
em
en
t
Achieved Higher Fly ash absorption & lower Sp. Elect. Energy cons.
Lower Sp. Elect. Cons.
7
Power saving by installing K turbo blowers for kiln firing & PC firing in place of conventional PD blowers. It has number of features such as High efficiency even at partial load Flow control by VFD Remote monitoring & operational control from CCR lower maintenance cost low noise & vibration Life of more than 15 years HMI colour display of parameters like discharge
pressure, inlet flow, air temperature, speed of motor, input power etc.
Achieved energy saving 40 % in PC firing & 51 % in Kiln firing blowers.
Also achieved better run time & less maint. expenses
8
Energy saving by optimizing compressors for pre-clinkerization & post-clinkerization by centralizing the compressors in their respective headers with installation of Intelligent flow controllers. Godrej IFC installed at the outgoing lines after the Air dryers to control the flow & maintaining the constant pressure in the application within the variation of 1 psig. This system facilitate to run the compressor in a very optimized way by maintaining desired air pressure. This system prioritizes & sequences the compressors according to their efficiency, thus reducing the loss of productive energy. Through this system all the compressors can be controlled & operated from desk.
9
Savings from optimization of Compressors:
POST -CLINKERISATION PRE-CLINKERISATION
Daily energy saving achieved 1388.61 KWh/day 1826.85KWh/day
Energy saving per year 458241.3KWh/year 602860.5KWh/year
% Energy savings achieved 11.36% 12.29%
10
Modification of cooler fans’ inlet Bell Mouth reduced the suction pressure from 10 to 4 mbar, because of less resistance.
Before modification
After modification
Increased pressure drop across fan, because of small diffuser placed
Decreased pressure drop across fan, By installing new bell mouth
Achieved energy saving of 232 Kwh/day
11
• Savings achieved for 2A = 94.08 ( Kw/Day) • Savings achieved for 2B = 138 (Kw/Day) • Budgeted Kiln running Hrs 2014 = 6952 Hrs • Hence, Kwh saving in 2014 = 67226 Kwh/Annum • Rs. Saving = 2,62,180 Rs./Annum
12
Optimization of Raw Mill dam ring height Saving in Specific Power.
Saving: 1 KWh/tclk (96 Lacs Rs. per annum)
Increase Raw Meal Residue on 212 Micron from 3.8 to 4.2 % .
Saving: 0.40 KWh/tclk ( 38.4 Lacs Rs. per annum).
Sepol vent air adjusted (10% of the total air) by installing VVVF drive in
Sepol bag filter fan. Saving: 13 kWh per mill ( 15.4 Lacs Rs. per annum )
13
Bang !
Daily Walk-by inspection
• Simple visual, audible, smell and touch inspection of the equipment or area
– Reading parameters, such as vibration, voltage, current, fault messages, etc.
– Observing items such as slip ring-carbon brush contact on MV motors
• Blowering, cleaning, greasing, oiling and also finding out the abnormal condition of the equipments.
• Sharing information to the internal and external customer
Burning smell,
Chemical smell
Vibration and
temperature
monitoring
Unusual Sound,
Noise
Oil, water, grease leaks,
cleanliness of the area, loose
bolts, smoke,
....and many more
14
Vibration Monitoring & analysis of major drives
Oil analysis of all Power & Distribution Transformer
IR/PI Value Testing of Electrical Equipments
Protection Relay Testing during annual shutdown .
Overhauling of HT/LT Motors during annual
shutdown as per Conditioning Monitoring Report therefore no motors failures during last 3-4 yrs
Thermography of LT switch gears done & its point attended.
HT/LT Switchgears Maintenance during annual shutdown.
Pre
ven
tiv
e
Main
ten
an
ce
Service
Replace
Condition
Monitoring
15
70
80
90
2011 2012 2013 2014 2015 MayYTD
79.57 78.99
76.45 77.34 76.13
16
0
1
2
3
4
5
6
7
8
9
10
2011 2012 2013 2014 2015 MayYTD
0.57 1.35
2.26 1.98
4.82
600
620
640
660
680
700
720
740
760
780
800
2011 2012 2013 2014 2015 MayYTD
718 722
714 718
735
Energy Efficiency Measures Taken in
CPP
17 2015
18
15 MW KHI
MP Turbine
15 MW TRIVENI
HP Turbine
Completed retrofitting of Kawasaki supplied Steam Turbine (Fully Condensing
type) with a new turbine (bleed cum condensing type) of similar capacity
consisting of LP and HP heaters to achieve the objective of improving the
Turbine Efficiency and Heat Rate.
MP Turbine(Existing)
Heat Rate (kCal/kWh) 3045
HP Turbine(New)
Heat Rate (kCal/kWh) 2445
Net heat rate saving after retrofit of the turbine
Kcal/Kwh 600.00
Annual savings(approx) Rs 4.5 Crores
Fuel savings (approx) Tons/Day 50
19
2011 2012 2013 2014 1. 100% Loading of HP turbines. 2. Maintaining design vacuum
levels across the STGs . 3. Online Steam leakage arresting. 4. Good Quality of coal.
S H R (Kcal/kwh)
3720 3658 3608 3521
Coal (Lac Tons) 3.97 3.66 3.17 2.93
20
2012 2013 2014 1. Installation of VVVF
drives for reduction in Aux Power
2. FRP blades replaced with aerodynamic fans in Cooling Tower
Aux.Power Consumption (%)
12.19 11.41 11.24
Aux.Power Units (Mio Kwh)
37.47 33.12 33.04
Coal Consumption (Lac Tons/annum)
3.66 3.17 2.93
Benefits of ISO 50001-2011
Certification
21 2015
22
With ISO 50001-2011 certification , our organization achieved many benefits, some are as below:
This standard has helped a lot to meet current and future voluntary/ mandatory energy efficiency targets or GHG emission reduction legislation. It will help to reduce greenhouse-gas (GHG) emissions and carbon footprint.
Increased energy savings which will reduce energy costs for producing one ton of cement via a structured approach of managing energy consumption.
With this system we know better about equipment efficiency. By integrating our existing management systems, we can align our Energy Management System (EnMS) with existing management systems for additional organizational benefits.
23
Increased energy awareness among staff members at all levels.
Improved corporate image and credibility with all stakeholders and customer.
Enhanced security of energy supply as we have identified our energy risk exposure in areas within the organization and getting remedial measure against it.
Improved operational efficiencies and maintenance practices
24
A significant improvement of the energy performance level from an initial energy baseline.
A systematic approach (plan-do-check and act) that leads to continuous energy efficiency improvement. ISO 50001 enables organizations to:
Develop a policy for more efficient use of energy
Fix energy efficiency targets and objectives to meet the policy.
Use data to better understand and make decisions concerning energy use and consumption
Measure the results of energy efficiency improvements
Review the effectiveness of the energy policy.
Continual improvement in efficiency through Energy management system.
25
ISO 50001 facilitates engagement (commitment and agreement) of management and has a positive contribution towards the energy targets.
EnMS creates awareness and a commitment about energy (i.e. consumption, use, efficiency, renewable sources) within the organization.
It improves the ability of organizations to mitigate energy risks.
It strengthens the competitiveness of organizations and reduces the impact of price fluctuations.
ISO 50001 fecilitate the establishment of a benchmarking process.
EnMS allows organizations to gain credible external visibility of energy saving measures.
26